Golf club head with multi-component contruction

ABSTRACT

A golf club head with a multi-component construction. The golf club head can include one or more components such as inserts, panels, plates, or body members that fasten to one another to form a club head body or that fasten to a club head body. The club head can include one or more components that snap-fit into a club head body. An insert can be made entirely or partially of plastic.

CROSS REFERENCE TO RELATED APPLICATION

This application claims priority to U.S. Provisional Application No.61/513,509, filed Jul. 29, 2011, the contents of which are herebyincorporated by reference in their entirety.

FIELD OF THE INVENTION

This application generally relates to golf club heads, particularly golfclub heads with multi-component constructions.

BACKGROUND OF THE INVENTION

Historically, an engineer will design a golf club in way that seeks tooptimize multiple properties of the finished club. The engineer willchose a shape and size for a club head based on aerodynamics, PGA rules,manufacturing capabilities, and consumer preferences. Within a clubhead, the engineer will design a mass distribution that provides anacceptable overall compromise of moment of inertia, center of gravity,and weight for the variety of customers who may purchase the club. Oncethe structure of the club head is designed, it will be finished withcolors, surface treatments, logos, and trim in hopes that wide range ofpeople will find the club head attractive. Sometimes a golf company willoffer a club in two or a few different finishes and trim levels, inhopes of appealing to more golfers.

Because a number of properties of a club head are influenced by massdistribution and materials, designing a golf club has traditionally beena one-size-fits-all exercise. While some clubs are offered withadjustable weight members or shafts, many properties such as massdistribution, color, aerodynamics, and turf interaction reflect alowest-common-denominator design paradigm. To offer consumers variety inthese properties, golf companies generally must design an entirely newclub.

SUMMARY

The invention provides a club head with one or more components that canbe easily attached together or to a body member to form a playable club.Components of the invention are separable and re-coupleable and furthermay be interchangeable. In some embodiments, components may be assembledwithout the use of adhesives, screws, and/or welding. Multi-componentclub construction allows a golf company to provide personalized clubs.Each club can be made to appeal to an individual golfer, and thequalities of the club can rise to meet the individual golfer's higheststandards, rather than reflecting the lowest-common-denominator found inmass-produced clubs.

Further, the invention offers club heads that may include weightelements that can be removed and replaced. Such weight elements caninclude specialized tool-mating surfaces and can be used additionally asa convenient assembly mechanism for the interchangeable components.

Another aspect of at least one of the embodiments described hereinincludes the realization that it would be advantageous to have a clubhead with a removable insert panels that include materials of differentweights and densities so that different panels can be interchanged todistribute mass differently. This allows weight to be distributed withina club head according to a golfer's individual desires.

In certain aspects, the invention provides a club head in which a bodymember has an opening for a crown insert and an attachment feature (suchas a flange) with a crown insert attached there. The crown insert can bea lightweight material (e.g., plastic). In some embodiments, a crowninsert is divided by strut-like divider elements, which can modulate theclub head physics properties. For example, the dividers may be flexible,non-plastic ribs that divide the crown insert into four plasticsections.

In some embodiments, a club includes a releasably attached weight memberthat can be added or interchanged with one another to adjust the clubhead weight, center of gravity, moment of inertia, or a combinationthereof. The weight members may have threaded posts that can be screwedinto corresponding threaded holes in the club head.

In certain aspects, the invention provides a club head having a bodywith an opening to receive an insert panel. An attachment feature (suchas a flange) at the opening presents a surface for attaching the insertpanel. The surface may optionally have holes on or through it. The holescan increase surface area and thus increase bonding strength of anadhesive used to attach the insert. Alternatively, the insert may have aplurality of protrusions to extend through the holes for attachment(e.g., posts that exhibit a tight press-fit; barbed posts; threadedposts to receive a nut element; etc.). A gasket may be positioned at theflange to dampen vibration or modulate weight.

In some embodiments, the insert is attached to the body by a snap-fitassembly, without the use of adhesives or welding. For example, thesnap-fit assembly can include cantilevers with protruding tips and arecess corresponding to each tip (e.g., cantilevers on body member andrecesses on insert, or vice versa). In some embodiments, the snap-fitassembly includes a collar adapted to be swaged onto a post forattachment and unscrewed with a wrench for removal.

Different inserts can be provided as a set, or as a variety ofindividual items to be purchased at a store, thus allowing a golfer tocustomize their club.

In certain aspects, the invention provides golf club head in which abody has a striking face, a heel-side skirt portion, a toe-side skirtportion, and a hosel. Further, a shaft-mounting structure within thebody member couples a shaft through the hosel which is fastened in placevia a shaft bolt. The club head further has a sole plate or sole insertthat is fastened in place at least in part by the shaft bolt. In someembodiments, removing the shaft bolt with a tool allows the sole insertto be manually separated from the club head with no other tools.

In certain aspects, the invention provides golf club head in which abody has a strike face area, a hosel, and an opening with a perimeter. Aweight member is releasably attached to the body and an insert panel isreleasably held in place over the opening at least in part by the weightmember. There may further be a flange disposed at the perimeter of theopening. The insert panel may further include a hole through which aportion of the weight member extends when attached to the body memberand an attachment feature spaced away from the hole for coupling to thebody member.

In other aspects, the invention provides a set of inserts forcustomizing a golf club. The set includes at least two insert panels.They are similarly shaped around their perimeters, so that they can beinterchangeably mated to a golf club. They can differ in appearance(i.e., color). In some embodiments they have different shapes acrosstheir surfaces, for example, to modulate and tune a club head'saerodynamics.

Inserts, panels, plates, body members, and components according to theinvention can be opaque, translucent, or transparent. They can beattached to one another or to club heads through the use of barbedposts, adhesive, protruding bosses for coupling via a shaft screw,recesses for receiving a protruding tip of a cantilever, andswage-on/twist-off fastening mechanisms as discussed herein.

Further, in accordance with an embodiment, a golf club head can comprisea body member comprising at least one opening for receiving a crowninsert, the body member comprising at least one body attachment featurefor attaching the body member to the crown insert, and a crown insertattached to the body member, a majority of the crown insert comprised ofplastic, the crown insert comprising at least one crown attachmentfeature for attaching the crown insert to the body member, the crowninsert comprising at least one divider element separating the crowninsert into a plurality of plastic portions.

In accordance with another embodiment, a golf club head can comprise abody member comprising at least one opening for receiving a crowninsert, the body member comprising at least one body attachment featurefor attaching the body member to the crown insert, the at least one bodyattachment feature comprising a plurality of openings on either amounting surface of the body member or a plurality of openings on agasket member connected to the body member, and a crown insert attachedto the body member, the crown insert comprising at least one crownattachment feature for attaching the crown insert to the body member,the at least one crown attachment feature comprising a plurality ofpost-like structures configured to be received within the plurality ofopenings.

In accordance with another embodiment, a golf club head can comprise abody member comprising at least one opening for receiving a sole insert,the body member comprising at least one body attachment feature forattaching the body member to the sole insert, the at least one bodyattachment feature comprising a first attachment flange having an angledcross-sectional profile, a sole insert attached to the body member, thesole insert comprising at least one sole attachment feature forattaching the sole insert to the body member, the at least one soleattachment feature comprising a second attachment flange configured tocontact the first attachment flange, wherein the sole insert isconfigured to be attached to the body member by a snap-fitconfiguration, without the use of adhesives or welding.

In some aspects, the invention provides a golf club head in which thebody has an opening shaped to connect to an insert component. There is abore through the hosel and sole so that a removable shaft can beconnected to the club head. The insert is fastened into place byfastening a shaft to the assembled club head, which, for example,compresses the insert to the body due to a compressive force between aferrule fixed on the shaft and a shaft screw extending into the shaftfrom the sole of the club head.

In other aspects, the invention provides a golf club head in which twocomponents are assembled along an attachment perimeter. At least part ofthe attachment perimeter is wavy (for example, when projected onto aplane, the attachment perimeter appears as a line having at least threeinflexion points, optionally four or five, that can be connected withinthe plane by an arc having no inflexion points).

In other aspects, the invention provides a multi-component golf clubhead in which one component is malleable, for example, made of rubber.The malleable or deformable component can be mated with, and fixed to, afeature on another component (e.g., the club head body) to form anassembled club head. In this way, the malleable component can provide aflap, for example, to act as a cover for a port or hole. In someembodiments the malleable component mates to a raised, rigid boss. Themalleable material can include rubber, PVC, silicon, or a similarmaterial.

In other aspects, the invention provides a multi-component golf clubhead in which one component fastens to another through the use of a cam.For example, the cam may be part of a lever, which can function as ahandle to release the cam, thereby releasing one component from another.In some embodiments, releasing the cam releases an insert from acorresponding hole on a club head body. The cam member may be providedwith a tool engagement surface. The cam may be disposed in a mechanismthat drives one or more engagement hooks to hook around a part of theclub head to hold a component in place.

In other aspects, the invention provides a golf club head having aninsert adapted to be coupled to an opening, or cutaway, in the club headbody. The insert may be fastened to a shaft of the golf club. While theinsert is visually mated to the club head body around an attachmentperimeter, by being fastened to the shaft directly (i.e., while the clubhead body is also fastened to the shaft directly), the club headexhibits very appealing playability characteristics for amulti-component club head. For example, in some embodiments, energy fromthe impact of a shot is transmitted through the shaft and does notinterfere with the coupling of the insert to the body.

In certain aspects, the invention provides a method of providing acustomized golf club head by receiving a consumer's selection of anoption and storing the selection in a tangible, non-transitory memory. Adigital file with the information about a club head including theselected option is created by a computer processor coupled to thememory. The information is transferred to a production site and acustomized club head including the selected option is produced. Forexample, a consumer's selected option can be a choice of insert to beprovided with the club head. In a related aspect, the invention providesa system for providing a customized golf club. The system includes acomputer with a tangible, non-transitory memory coupled to a processor.The system is used to receive a consumer's selection of an option andstore the selection in the memory, then create a digital file includinginformation about a club head including the selected option. Devices ofthe system transfer the information to a production site and write afile comprising billing and shipping data for use in a sale transaction.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features and advantages of the present embodiments willbecome more apparent upon reading the following detailed description andwith reference to the accompanying drawings of the embodiments, inwhich:

FIG. 1 is a bottom perspective view of a golf club head in accordancewith at least one embodiment;

FIG. 2 is a cross-sectional view, taken along line 2-2, of the golf clubhead of FIG. 1;

FIG. 3 is a top perspective view of the golf club head of FIG. 1, with acrown portion removed;

FIG. 4 is a cross-sectional view, taken along line 4-4 of FIG. 3, of thegolf club body member of FIG. 1, with the crown member attached to thebody member;

FIG. 5 is a top plan view of a plastic crown insert in accordance withat least one embodiment;

FIG. 6 is a top plan view of an alternative embodiment of the crowninsert of FIG. 5; and

FIGS. 7 and 8 are embodiments of detail C, shown in FIG. 4; and

FIG. 9 is a partial view of a club head and insert according to anembodiment.

FIG. 10 shows a club with sole plate.

FIG. 11 is a bottom view of a club head with detachable sole plate.

FIG. 12 shows a sole plate according to certain embodiments.

FIG. 13 is a cross section across the line in FIG. 11.

FIG. 14 illustrates a detachable sole plate fixed into a place with aweight member.

FIG. 15 shows a weight member for fixing a sole plate into place.

FIG. 16 shows a club head configured to receive a sole plate.

FIG. 17 shows a club head with slotted flange and deformable crownpanel.

FIG. 18 shows a club head with slotted flange.

FIG. 19 shows insertion of a deformable crown panel into slotted flange.

FIG. 20 shows a club head with flange with holes.

FIG. 21 shows a crown panel with barbed posts for insertion into holesin a flange.

FIG. 22 shows a cross-sectional view of barbed posts and flange withholes.

FIG. 23 is a side view of a club head and crown panel with barbed posts.

FIG. 24 shows a club head with button tabs and attachable crown panel.

FIG. 25 shows the club head and panel in FIG. 24 assembled.

FIG. 26 shows a club head and sole plate with pre-attached adhesivestrips.

FIG. 27 shows a club head with cage structure and attachable crownpanel.

FIG. 28 is a cross-sectional view of a club head assembled with a rapidfastening system.

FIG. 29 illustrates a method of rapidly fastening a sole plate to a clubhead.

FIG. 30 shows a threaded post for use in a rapid fastening system.

FIG. 31 shows a barbed post for attachment to a hole.

FIGS. 32A-32C illustrates a mechanism of a rapid fastening system.

FIG. 33 shows a hosel/face member and a body member.

FIG. 34 shows the components of FIG. 33 assembled with a rapid fasteningsystem.

FIG. 35 shows a club head with voids and a translucent insert panel.

FIG. 36 shows an opaque insert panel for a club head with voids.

FIG. 37 shows a club head assembled with an insert panel.

FIG. 38 shows a face member and body member with corresponding threadedportions.

FIG. 39 is a top view of a face member and body member with threadedportions.

FIG. 40 shows a club head body with closeable strap and crown panel withgroove.

FIG. 41 shows an assembled club head with crown panel strapped to body.

FIG. 42 is a top view of the club head shown in FIG. 41.

FIG. 43 shows a club head face member with cantilevered posts.

FIG. 44 shows a tool for separating a cantilevered attachment point.

FIG. 45 shows a club head body member with recesses for receivingcantilever tips.

FIGS. 46-49 show configurations of cantilevered posts and recesses.

FIGS. 50A-50C show a club head with component with cam mechanism.

FIG. 51 is a detail view of the cam mechanism of FIGS. 50A-50C.

FIG. 52 illustrates radii around a cam axis.

FIGS. 53A-53D show a club head with cam and engagement hooks.

FIGS. 54A-54B show an engagement member for engagement hooks.

FIGS. 55A-55B show a component coupling system.

FIG. 56 shows a shaft collar for using a coupling system.

FIGS. 57 and 58A-58C show a club head with crown component.

FIG. 59 shows a club head with crown component.

FIG. 60 shows a snap-fit catch for a component.

FIG. 61 shows a club head with a flap component.

FIGS. 62A and 62B show use of a flap component to fasten a club headcomponent.

FIG. 63 shows a club head with removable sole component with magnets.

FIG. 64 is a top view of a boss member with magnet therein.

FIG. 65 is a cross-sectional view of a set of magnet bosses.

FIG. 66 shows an insert panel.

FIG. 67 shows a club head body.

FIG. 68 shows magnets coupling an insert to a club head body.

FIG. 69 shows a display for receiving option selections.

FIG. 70 is a block diagram of a method for providing a customized clubhead or golf club according to certain embodiments.

FIG. 71 is a block diagram of a system for providing a customized clubhead or golf club.

DETAILED DESCRIPTION

The present application is directed to golf club heads, and particularlyto golf club heads with multi-component structures. While theembodiments disclosed herein include club heads for wood-type clubs, itis contemplated that one or more of the concepts described herein canfurther be used for other types of club heads, including but not limitedto irons and putters.

With reference to FIGS. 1-4, a golf club head 10 can comprise a ballstriking face 12, a crown 14, a sole 16, and a hosel 18. The golf club10 can further comprise a body member 20, a face insert 22, at least onesole insert 24, and at least one crown insert 26. In some embodiments,the body member 20 can comprise a metallic member that includes aplurality of openings for receiving the face insert 22, sole insert 24,and/or crown insert 26. In some embodiments, the body member 20 can becomprised, at least in part, of a 6-4 titanium alloy, though other typesof material are also possible. As illustrated in FIGS. 1-4, in someembodiments the body member 20 can comprise a portion or portions of theball striking face 12, crown 14, and/or sole 16.

With reference to FIG. 3, in some embodiments the hosel 18 can comprisea sleeve 28 that permits interchangeability and/or adjustability of agolf club shaft. In some embodiments the sleeve 28 can be comprised of6062 aluminum, though other types of materials are also possible. Insome embodiments, the sleeve 28 can be adjusted so as to adjust the lieangle of the club head 10. Other types of material and/or structure canalso be used for the sleeve 28. U.S. Pat. No. 7,789,766, the entirecontents of which are incorporated by reference herein, describesvarious adjustability features of a sleeve similar to sleeve 28.

With reference to FIG. 1, in some embodiments the hosel 18 can alsocomprise a hosel sleeve screw 30 configured to releasably attach one ormore components of the hosel 18 to the club head 10. The screw 30 can becomprised, for example, of 304 stainless steel produced using atraditional screw machine with a T20 head, though other types ofmaterials and screws are also possible. Additionally, other types offasteners besides screws can be utilized. In some embodiments, the screw30 can be inserted within a recess 31 in the body member 20.

With continued reference to FIGS. 2 and 4, the face insert 22 cancomprise at least a majority, for example by volume and/or mass, of theball striking face 12. In some embodiments, the face insert 22 can formapproximately 60 percent of the volume and/or mass of the ball strikingface 12. In some embodiments, the face insert 22 can form approximately70 percent of the volume and/or mass of the ball striking face 12. Insome embodiments, the face insert 22 can form approximately 80 percentof the volume and/or mass of the ball striking face 12.

The face insert 22 can be comprised of metal, or other suitablematerial. In some embodiments the face insert 22 can be comprised of thesame material as the body member 20. In some embodiments the face insert22 can be comprised of 6-4 titanium. In some embodiments the face insert22 can be comprised of more than one type of material and/or more thanone layer of material.

In some embodiments, the face insert 22 and/or ball striking face 12 cantransition into the crown 14 and sole 16 at a transition point or area.The transition point or area can be a location where a line drawnperpendicular to a tangent line extending along the surface of the clubhead 10 at the transition point or area forms an approximately 45 degreeangle relative to a vertical plane passing through the club head 10.

With continued reference to FIGS. 2 and 4, in some embodiments the crowninsert 26 can comprise at least a majority, for example by volume and/orweight, of the crown 14. In some embodiments, the face insert 22 canform approximately 60 percent of the volume and/or mass of the ballstriking face 12. In some embodiments, the face insert 22 can formapproximately 70 percent of the volume and/or mass of the ball strikingface 12. In some embodiments, the face insert 22 can form approximately80 percent of the volume and/or mass of the ball striking face 12.

The crown insert 26 can be comprised of composite, reinforced plastic,thermoplastics, or other suitable material. With reference to FIG. 5, insome embodiments the crown insert 26 can be comprised entirely ofinjection molded material. In some embodiments, the insert 26 can becomprised of single or multi-density metallic or non-metallic material.

In other embodiments, and with reference for example to FIG. 6, thecrown insert 26 can have one or more portions 38 that are comprised ofplastic, along with one or more flexible divider elements 40 thatconnect the portions 38 together. In some embodiments, a majority of thecrown insert 26 is a thermoset or thermoplastic material, which mayoptionally be reinforced with secondary fibers, such as carbon, glass,wood, plant or metal such as, for example, a plastic. In someembodiments, the portions 38 can be interchangeable. The dividerelements 40 can be comprised, for example, of any metallic ornon-metallic material desirably having a density less than that of thebody member 20. In some embodiments, the divider elements 40 can bebonded with the remaining portions 38 of the crown insert 26. In someembodiments the divider elements 40 can be formed integrally with theremaining portions 38. In some embodiments, the divider elements 40 candivide the crown insert 26 into four portions 38, though other numbersof portions are also possible. The divider elements 40, along with theplastic portions 38, can give the crown insert 26 flexibility andreduced weight as compared with crown inserts made of metal or carbonfiber. The added flexibility can inhibit the plastic material of crowninsert 26 from cracking or fracturing. In some embodiments, if theflexibility is too great, and negatively affects the sound/tuning of theclub head 10, additional measures can be taken to reinforce the clubhead 10 and/or to create better sound qualities. For example, a gasketcan be added between the crown insert 26 and the body member 20, ormaterial such as latex can be added between the crown insert 26 and thebody member 20, to act as a sound barrier. In some embodiments, asupport member can extend generally from the sole 16 to the crown 14 canbe added to the club head 10.

In some embodiments, the club head 10 can have a density ratio betweenthe body member 20 and an insert. For example, in some embodiments theratio of the density of the body member 20 to the crown insert 26 can be1.5. In some embodiments, the density ratio between the body member 20and one of the inserts can be approximately 2.0, 2.5, 3.0, 2.5, 4.0, orhigher than 4.0. Other density ratios are also possible.

Overall, the use of plastic (such as, for example, polyurethanes,polyesters, epoxy resins, phenolic resins, and carbon composites) in thecrown insert 26 can, at least in some embodiments, not only reduceweight but also facilitate a generally transparent, or at leastpartially transparent, club head 10. Transparency can allow a user toview whether material has accumulated inside the club, and/or whetherthe club head 10 is damaged or showing signs of wear on the inside. Insome embodiments, the crown insert 26 can be translucent. In someembodiments the crown insert 26 can be comprised of a photochromicmaterial. The plastic can reduce weight in the crown 314, thus allowingthe weight that otherwise would been located in the crown 314 to beoptimally redistributed to other areas of the club head 310 to optimizea location of a center of gravity, for example, or optimize moments ofinertia in the club head 310.

With continued reference to FIGS. 2-4, the crown insert 26 and/or bodymember 20 can comprise at least one mounting feature 42. The mountingfeatures 42 can be used to attach the crown insert 26 to the body member20 or other component of the club head 10. For example, with referenceto FIG. 4, in some embodiments the mounting features 42 can compriseattachment flanges, permitting the crown insert 26 to be adhesivelyattached, for example, or welded, to the body member 20. In someembodiments, mounting features can comprise non-threaded attachmentsthat clamp and unclamp with the push of a finger, hand, or tool. Themounting features can include one-touch fasteners and may have internalsprings. A press-fit or snap-fit assembly can be used. In someembodiments, a tool can be used to release an insert, such as the crowninsert, to replace it with a different crown insert.

With reference to FIGS. 3, 4, 7 and 8, in some embodiments the mountingfeatures 42 on the crown insert 26 can comprise post-like structures 44that are configured to be received within corresponding mountingfeatures 42 on the body member 20. The corresponding mounting features42 on the body member 20 can comprise, for example, openings 46 on amounting surface 48 of the body member 20. In some embodiments, and withreference to FIG. 8, a gasket member 47 can be placed between the bodymember 20 and crown insert 26. For example, the gasket member 47 can beadhesively attached to the body member 20. In some embodiments, insteadof the body member 20 having openings 46, the gasket member 47 insteadcan include the openings 46. Alternatively, in other embodiments boththe gasket member 47 and body member 20 can include openings, and thepost-like structures 44 can be inserted through the gasket member 47 andinto the body member 20.

With continued reference to FIGS. 3, 4, 7, and 8, the post-likestructures 44 and openings 46 can be spaced around the club head 10,such that the crown insert 26 is secured firmly to the body member 20 ina plurality of locations. For example, the mounting surface 48 caninclude six openings 46 spaced generally equally around the club head10, and the crown insert 26 can include six post-like structures 44 thatare configured to be received within the six openings 46. In someembodiments, the post-like structures 44 can press or snap-fit into theopenings 46, and the crown insert 26 can be held in place without theuse of any additional adhesive, welding, etc. In some embodiments,additional adhesive can be used, for example between an outer edge ofthe crown insert 26 and the mounting surface 48. In some embodiments,the crown insert 26 can be mounted to the mounting surface 48 withoutthe use of post-like structures 44 or openings 46. For example, in someembodiments the crown insert 26 can be attached purely by adhesives,welding, mechanical attachment, etc.

With reference to FIGS. 1, 2 and 4, in some embodiments the sole insert24 can comprise at least a majority, for example by volume, of the sole16. The sole insert 24 can include composite, plastic, or any othersuitable material. In some embodiments, sole insert 24 is made ofinjection molded plastic. Further, sole insert 24 may have secondarycoatings or be co-molded to other materials. Co-molded materials andsecondary coatings can include ceramics, anodizing, or similar. In someembodiments, a secondary coating or co-molded material includes alow-friction polymer. For example, sole insert 24 may have ahard-anodized coating infused with a low-friction polymer such as afluorinated polymer (e.g., poly-tetrafluoroethelyne (PTFE), sold underthe trademark TEFLON by DuPont). Suitable coatings are discussed in U.S.Pub. 2011/0118057, the contents of which are hereby incorporated byreference in their entirety for all purposes.

Sole insert 24 can have a variety of shapes and sizes. For example, thesole insert 24 can have an oblong and/or generally hourglass-like shape,such as that shown in FIG. 1. Other shapes and sizes are also possible.As with the crown insert 26, the sole insert 24 can also be comprised ofa material that is lightweight, and/or less dense, than that of the bodymember 20, so that weight can be redistributed as desired to other areasof the club head 10, and a center of gravity of the club head 10 can forexample be pushed towards the back and heel side of the club head 10,and/or moments of inertia can be optimized. In some embodiments, amovement of weight can advantageously increase a moment of inertia ofthe club head 10, causing reduced unwanted twisting or movement of theclub head 10 upon impact with a golf ball.

In some embodiments, there can be more than one sole insert 24. In someembodiments, a sole insert 24 can have a divider, similar to at leastone of the embodiments of the crown insert described herein.

With continued reference to FIGS. 1, 2, and 4, the sole insert 24 cancomprise at least one mounting feature 42. The mounting features 42 canbe used to attach the sole insert 24 to the body member 20 or othercomponent of the club head 10. With reference to FIG. 2, in someembodiments the mounting features 42 of the sole insert 24 and bodymember 20 can comprise one or more attachment flanges. For example, thesole insert 24 can include a first attachment flange 50 that extendsinwardly from the sole insert 24. In some embodiments, the firstattachment flange 50 can extend at a right angle relative to a surfaceof the sole insert 24. The attachment flange 50 can be configured tocontact and/or mate with a corresponding attachment flange 52 on thebody member 20. The attachment flange 52 can have a bent profile, forexample, and extend inwardly from the body member 20 (e.g. towards aninterior volume of the club head 10).

In some embodiments, the sole insert 24, and/or other inserts on theclub head, can be configured to snap-fit into the body member 20. Forexample, in some embodiments, at least one surface of attachment flange50 can contact and press against at least one surface of the attachmentflange 52 of the body member 20, helping to hold the sole insert 24 inplace relative to the body member 20. The insert 24 can be held in placeby friction. In some embodiments the sole insert 24 can include anadditional flange 54, which contacts a flange 56 on the body member 20.The flanges 54 and 56 can also be configured to contact one another,and/or snap-fit in place or be attached by adhesive, welding, etc. Insome embodiments, the body member 20 can include a flange or flangesthat are biased in a first direction, such that when an insert ispositioned within the club head 10, the flanges are forced away from thefirst direction towards a second direction, the flanges pressing backagainst the insert towards the first direction to hold the insert inplace again once the insert has been attached. For example, in someembodiments the flange 52 can be biased in a first direction towards theback end of the club head, and pushed towards a second direction towardsthe front of the club head when the sole insert 24 is attached. In someembodiments, the body member 20 can include flanges with ends that areinitially biased towards one another, and when an insert is attached,the ends are pressed away from one another, the force of the ends of theflanges holding the insert in place. In some embodiments, adhesive,welding, and/or mechanical structures can be used to help hold one ormore inserts (e.g. the sole insert 24) in place within the body member20.

In certain embodiments, either crown insert, sole insert, any otherinsert such as a face insert or skirt insert (or combination thereof),or any other component is fastened to form a playable club by a mountingfeature that uses a threaded mechanism. For example, a mounting featuremay include a screw well such as, for example, those described in U.S.Pub. 2011/0111885, the contents of which are hereby incorporated byreference in their entirety for all purposes. Further, an insert may befastened into place by a screw through another portion of a club head.Threaded elements are discussed in U.S. Pat. No. 8,033,930; U.S. Pat.No. 7,771,290; U.S. Pat. No. 5,776,011; and U.S. Pat. No. 5,429,365, thecontents of which are hereby incorporated by reference in their entiretyfor all purposes.

In some embodiments, one or more inserts, such as sole insert and/orcrown insert 24, 26 can be configured to have a size larger than that ofa corresponding opening on the body member 20. When the sole insertand/or crown insert 24, 26 is inserted into the opening in the bodymember 20, the sole insert and/or crown insert 24, 26 can flexinitially, and/or the body member 20 can flex initially, and the soleinsert and/or crown insert 24, 26 can be held in place frictionally oncepositioned inside the opening. In some embodiments, the sole insertand/or crown insert 24, 26 can force one or more flanges 50 to act as aspring mechanism, applying a force on the sole insert and/or crowninsert to hold the sole insert and/or crown insert 24, 26 in placewithin the body member 20.

Other snap-fit constructions can also be used. For example, and withreference to FIG. 9, in some embodiments a body member 20 of a club headcan include one or more recesses, channels, openings, or otherstructures 58 along the inside or outside of the club head configured toreceive an attachment flange 60 on an insert 62, and to temporarily lockthe attachment flanges 60 and the insert 62 into place within the clubhead. The insert 62 can be removed, for example, by pressing on one ormore areas of the insert 62, such as the outside edges of the insert.

In some embodiments, screws, clamps, or other fasteners can be used toconnect, remove, and/or replace the inserts. In some embodiments,adhesive can be used to help hold an insert or inserts in place thatwill not be replaced.

In certain embodiments, two club head components can be joined, or acomponent can be joined to a body part, by an assembly method such asstaking, ultra-sonic welding, or heat staking. For example, The seams asshown in FIG. 4 provide surfaces that can be attached by these methods.In certain embodiments, components are assembled by heat staking. FIG.29 illustrates one way in which an assembly tool can access seams forassembly by heat staking.

Heat staking is a means of locking club head components together. Ingeneral, one of the parts to be assembled is designed to include aplastic post or tab which can be inserted through a hole or aperture inanother part and then permanently and inelastically deformed by thegeneration or application of heat by some tool surface which effectsplastic deformation. The variables which can be tuned include thecharacteristics of the particular plastic material employed includingits flow and melt temperatures, the nature and characteristics of thetooling employed and the geometries thereof, means by which the toolingmay be brought to bear against the plastic elements to be deformed, thechoice of method for effecting heating, and the parameters of pressure,time, and heat energy applied.

In one embodiment, a plurality of first thermoplastic components, orheat-stakes, may be located sporadically around the periphery of acomponent and a second component may comprise a plurality of secondthermoplastic components, or encapsulates, comprising receiving holeslocated in corresponding locations to the heat-stakes of the firstautomotive component. The heat-stakes may be inserted into the receivingholes and a staking device may be used to heat-treat a leading end ofeach heat-stake. This use of the staking device results in thedeformation of the heated leading end of the heat-stake such that a“mushroom cap” may be formed. The mushroom cap of each heat stakecommonly covers the corresponding receiving hole of the encapsulate.This resulting overlap results in the mechanical coupling of the firstand second components. The resulting retention force of a heat stakingprocess may be tuned by varying the amount of surface area of theencapsulate contacted by the heat-stake's mushroom cap as well as thecomposition states of the encapsulate and heat-stake.

A particular advantage of heat stake in club head assembly is that suchmethods operate well with dissimilar materials. For example, a plasticcomponent with stakes can be fastened to a metal component withreceiving holes by heat staking. Heat staking is discussed in moredetail in U.S. Pat. No. 6,840,755; U.S. Pat. No. 6,296,470; U.S. Pat.No. 5,871,784; U.S. Pat. No. 4,767,298; and U.S. Pub. 2008/0230948, thecontents of each of which are hereby incorporated by reference in theirentirety for all purposes.

In certain embodiments, two club head components can be joined, or acomponent can be joined to a body part, through the use of magnets,discussed in more detail below.

In some embodiments, the club head 10 can include an entire set ofdifferent inserts that can be easily removed and replaced. This canfacilitate consumer customization of the club head 10. For example, aclub head set could include a club head 10 with a body member 20, and aplurality of different thickness, density, weight, and/or transparencycrown or sole inserts. A user can select a desired insert or inserts,and quickly and easily attach the desired inserts. Advantageously, insome embodiments the inserts can press-fit or snap-fit into place withinthe body member 20, for example as described above. The inserts can beinterchangeable, and in some embodiments can comprise a kit, the partsof which can be tailored to specific golfer needs. In some embodiments,the customization could include choosing from a plurality of insertswith different indicia, designs, etc., including but not limited tocountry flags, favorite teams, etc.

With continued reference to FIG. 1, the club head 10 can further includeat least one weight member 58. The weight member 58 can removable, andcan be inserted into a portion of the body member 20. In someembodiments, addition of a weight member 58 can advantageously permitmore weight to be moved towards the heel of the club head 10. In someembodiments, the weight member can have a head 60 that has an outersurface that is generally flush with an outer surface of the body member20. The weight member 58 can comprise a weight screw, formed for examplefrom tungsten, stainless steel, such as 17-4, aluminum, or othersuitable materials. Other types and materials are also possible. In someembodiments, the weight screw head 60 can include one or more toolcavities 62. The tool cavities can be configured to receive a tool, suchas a specialized tool, that is configured to remove the weight screw 58.In some embodiments the tool cavities 62 can comprise two separateopenings. In some embodiments the tool cavity can comprise a generallystar-shaped opening for receiving a correspondingly-shaped tool. Othershapes and types of tool cavities are also possible. In some embodimentsthe club head 10 can be configured to receive various weight screws 58of different weight, so that the swing weight of the club head 10 can bealtered. For example, in some embodiments the weight screw 58 can becomprised of tungsten, and weigh approximately 10 grams. In someembodiments the weight screw 58 can be comprised of stainless steel, andweight approximately 6 grams. In some embodiments the weight screw 58can be comprised of aluminum and weight approximately 2 grams. Othermaterials and weights are also possible. The type and weight of weightscrew 58 used in the club head 10 can depend on an overall club headweight, a desired swing weight, a desired location of a center ofgravity of the club head 10, and/or a desired moment of inertia of theclub head 310. For example, the club head 10 can be designed, and aweight screw 58 can be selected, such that a center of gravity of theclub head 10 is located approximately 4 mm rearward from a geometriccenter point on the face insert 22, and approximately 4 mm above alowest point on the sole 16 when the club head 10 is at address. Otherlocations for the center of gravity are also possible.

In some embodiments, the ratio of the weight screw material density tobody material density (i.e. between weight screw 58 and body member 20)can be approximately 1.5. In some embodiments the density can beapproximately 2.0, 2.5, 3.0, 3.5, 4.0, or higher than 4.0. Other densityratios are also possible.

In some aspects, the invention provides a club head with a removable orinterchangeable component, such as a crown panel or sole plate, that isaffixed to the a club head body through the use of a mechanism in a clubhead that also provides other functionality. Through the use ofmechanisms that also provide other functionality, it is possible toprovide a club head with one, two, three or more separable panels thatfurther include no visible assembly mechanisms (e.g., protruding plastictabs, recessed holes, etc.) other than the mechanism associated with theother functionality.

FIG. 10 shows club head 64 with insert 62 and FIG. 11 is a bottom viewof club head 64. FIG. 12 shows insert 62 having boss 63 and clasp 66.Club head 64 is assembled by positioning clasp 66 on the inside edge ofthe insert hole in the bottom of the body of club head 64. Insert 62 isthen closed, using clasp 66 as a hinge, so that boss 63 comes proximalto repositionable shaft housing 65.

Club head 64 includes housing 65 to receive and mount a repositionableshaft in various dispositions. When a shaft is mounted in a hosel ofclub head 64, hosel sleeve screw 30 fastens the shaft into place. Asshown in FIGS. 10-13, hosel sleeve screw 30 can also serve to fix insert62 into position. Golf clubs including adjustable mechanisms, oradjustable mechanisms for golf clubs, suitable for operation with theinvention, are discussed in U.S. Pub. 2010/0041493; U.S. Pub.2011/0098128; U.S. Pat. No. 8,057,323, U.S. Pat. No. 1,879,117 and U.S.Pat. No. 3,096,982, incorporated by reference herein in their entirety.

As shown in FIG. 13, when insert 62 is installed in club head 64, clasp66 is entirely within the club head. Insert 62 is held in place securelyby hosel sleeve screw 30, which is associated with other functionalityof the club head (e.g., an interchangeable/repositionable shaft).

Further, as shown in FIG. 14, insert 62 can be held in place by one ormore of releasable weight component 58. FIG. 15 shows a weight component58 having two tool cavities 61 and a threaded post 63.

FIG. 16 shows club head 64 configured to receive insert 62 (here, a soleplate). Club head 64 includes boss 67 having a threaded hole to matewith threaded post 63. Club head 64 further includes attachment flange56 and repositionable shaft housing 65. Insert 62 can be positioned onthe base of club head 64 with 66 hooked therein. Weight component 58 andshaft screw 30 can then be tightened (e.g., with a tool), fixing inset62 there in place. One insight of the invention associated with clubswith most beneficial properties is the dual functionality of areleasable weight component to provide a customizable mass distributionwhile also providing a mechanism for fastening a separable component toa club head. Separable components are discussed in U.S. Pub.2011/0294589, the contents of which are hereby incorporated by referencein their entirety for all purposes. Here, the invention provides theability to finely-tune a club head to correct for a golfer's hook orslice by positioning the weight on a heel side, toe side, or both,through the use of a releasable weight component. Rather than simplyadding a mass of weight, the fastening mechanism of the presentinvention derives most desirable additional utility in unexpected waysby harmonizing the placement of releasable weights used to aid inimproving a golfer's shot with the fastening of releasable bodycomponents.

In some aspects, the invention provides club heads with separablecomponents that can be attached or removed without the use of tools.

FIG. 17 shows a club head 71 with slotted flange 77 and deformable crownpanel 75. As shown in FIG. 18, slotted flange can extend around anaperture in a club head, completely or in part. Crown panel 75 is thenpositioned so that a thin edge 79 is pressed against slotted flange 77,as shown in FIG. 19. Crown panel 75 deforms plastically or elastically(strictly speaking, it is an elastic deformation, which is sometimesreferred to as a plastic deformation). As shown in FIG. 19, panel 75 canbe bent so that it bows outwards, allowing thin edges 79 to be insertedinto slot 76 in slotted flange 77. As panel 75 is released, it tends toreturn to its original shape such that thin edge 79 fully inserts intoslot 76. In some embodiments, it is pushed entirely into place andadjusted by hand.

In some embodiments, a separable component is attached to a club head 81without tools through the use of one or more barbed posts. FIGS. 20-23show a tool-less removable panel attachment system. As shown in FIG. 20,club head 81 includes a flange 87 having one or more of hole 83therethrough. FIG. 21 shows an insert having one or more barbed post 89positioned and dimensioned to correspond to the holes 83. FIG. 22 showsa detailed cross-sectional view of barbed posts 89 and flange 87 withholes 83. When insert panel 85 is pushed into place, each barbed post 89pushes through a hole 83. The barbs deform plastically/elastically andretain insert 85 mounted securely on club head 81. FIG. 23 is a sideview of club head 81 and crown panel 85 with barbed posts 89 positionedto be attached together.

In certain embodiments, club head 81 is provided for use with one ormore disposable inserts 85. Each insert 85 can have a novel orinteresting color or pattern. A golfer chooses one that he or she findspleasing and inserts it into club head 81 through the use of the barbedposts (or any of the other suitable mechanisms such as those describedelsewhere herein). When the golfer wishes to remove insert 85, pullingit away from club head 81 snaps all of the barbed posts off, and theinsert is set aside. A golfer may use a tool, such as a thin, flatscrewdriver, to lift a first edge of insert 85 to aid in removing it.

In certain embodiments, the invention provides a club head with aremovable and re-attachable panel through the use of depressableengagement tabs. FIG. 24 shows a club head 91 with four of depressableengagement pad 92 and attachable crown panel 95. Crown panel 95 has fourreceiving holes 93 dimensioned to correspond to a button portion of thedepressable engagement pads 92. When crown panel 95 is pushed onto clubhead 91, pads 92 deform (e.g., bend inwards) and then snap into place.FIG. 25 shows an assembled club head 91. To remove panel 95, the buttonportion of pads 92 is depressed and panel 95 is lifted off.

Any suitable number of pads 92 may be included, and in any suitablearrangement.

In some embodiments, a removable or disposable panel is provided to beattached via adhesive. FIG. 26 shows a club head 101 and sole plate 103with pre-attached adhesive strips 105. Adhesive strips 105 can belocated to correspond to flange 107. Alternatively, plate 103 may notinclude adhesive strips 105, and they can be provided separately (e.g.,as double-stick tape). In some embodiments, plate 103 is fastened intoplace through the use of VHB adhesive tape, wet epoxy, or a combinationthereof. Fastening is discussed in U.S. Pub. 2011/0045921, the contentsof which are hereby incorporated by reference in their entirety for allpurposes.

In various embodiments, providing a club head with a body member and oneor more outer panels provides a club designer with opportunities fornovel arrangements of material to tune a mass distribution, to enhancestrength, to refine sound tuning, or modify coefficient of restitutionof a club head. For example, certain embodiments, a panel will be usedto cover what would otherwise be one or more holes in a club head body.Where the club head body includes a metal or other heavy material, andthe panel includes a plastic, composite, or other lightweight material,this can provide significant weight savings.

FIG. 27 illustrates a club head 111 having a crown panel 115 to cover acage portion 113 that includes one or more of hole 119 a, 119 b, . . .etc. Cage portion 113 can be surrounded by lip 117 dimensioned tocorrespond to an edge of panel 115. It may be found that thisconstruction of a club head provides excellent durability andcoefficient of restitution, while allowing for significant mass savings(relative to a club head without holes 119). Furthermore, panel 115 canbe customizable or interchangeable. In certain embodiments, panel 115has adhesive on an inner surface, barbed posts corresponding to holes inclub head 111, a thin edge corresponding to a slotted flange on clubhead 111, or any other suitable attachment mechanism such as thosedescribed herein.

In certain embodiments, a club head with a multi component constructionmakes use of a rapid fastening system such as the bolt assembly soldunder the trademark POPBOLT by Emhart Technologies (Shelton, Conn.).FIG. 28 is a cross-sectional view of a club head 121 assembled with arapid fastening system. As shown in FIG. 28, a panel 125 is mounted to aflange in club head 121. A bolt post member 124 protrudes through a holein the flange, and a collar 127 is affixed thereto. In certainembodiments, post member 124 is a threaded bolt and collar 127 is athreaded nut.

In some embodiments, post member 124 and collar 127 are components of arapid fastening system. FIG. 29 illustrates a method of rapidlyfastening a sole plate to club head 121. As shown in FIG. 29, postmember 124 is provided by a separate bolt. Collar 127 is positionedthereon and tool 129 is used to fasten collar 127 to post member 124.When using a system such as the bolt assembly sold under the trademarkPOPBOLT, collar 127 is swaged to post member 124. Post member isthreaded to begin with and swaging collar 127 to post member 124 causescollar 127 to become threaded. Collar 127 can then be removed throughthe use of a wrench. Swaging collar 127 to post member 124 is describedin FIG. 32.

In certain embodiments, a post member 128 is formed integrally withinsert 125 and protrudes from a surface of the insert, as shown in FIG.30. In some embodiments, a protruding post is a barbed post 89. Insert125 with barbed post 89 can be used in club head 121, even where clubhead 121 can also, separately, be used with a rapid fastening system. Insome embodiments, club head 121 has a rapid fastening system used tofasten insert 125 in place (e.g., by swaging collar 127). Then, collar127 is removed with a wrench and insert 125 is removed and set aside.Another insert 125 that includes barbed posts 89 is then fixed to clubhead 121 using the same holes. By these means, a club head can becustomized with a tool (for example, in a pro shop) by one method, butthen can be “field stripped” and re-customized out on the course withoutthe benefit of the tool system.

FIGS. 32A-32C illustrate the operation of a rapid fastening system suchas the bolt assembly sold under the trademark POPBOLT by EmhartTechnologies (Shelton, Conn.). As shown in FIG. 32A, a bolt or post isinserted through a hole (e.g., post 124 protruding from insert 125 isinserted through a hole in a corresponding flange on a club head body).FIG. 32B shows positioning collar 127 over post 124 through the use oftool 129. In certain embodiments, a tool 129 of a rapid fastening systemcarries collar 127 and positions it over post 124. As illustrated byFIG. 32C, operating a trigger on tool 129 swages collar 127 to post 124(simultaneously forming a threaded connection). Operating tool 129 alsobreaks off an excess portion of post 124 and removes it. Tool 129 canthen be taken away from the assembly site.

FIG. 33 shows a hosel/face member 131 and a body member 135 adapted tobe coupled together with a rapid fastening system. Face member 131 caninclude one or a number of post member 124, while body 135 has acorresponding number of inset boss 133 dimensioned so that post 124slides through a hole therein. In certain embodiments, collar 127 isthen positioned on post 124 and fastened into place as discussed aboveand as shown in FIG. 34. Suitable club heads for use with systems of theinvention are discussed in U.S. Pat. No. 7,959,522, the contents ofwhich are hereby incorporated by reference in their entirety for allpurposes.

In some embodiments, the invention provides a club head with a sole orcrown insert that press-fits or snap-fits into place from within theinside of the club head. FIGS. 35-37 show a club head body 142configured to receive internal insert 145. As shown in FIG. 35, clubhead body 142 can be separated from face member 141. Face member 141 ismounted to club head body by one or more of cantilever 173 (discussed inmore detail with respect of FIGS. 43-49, below).

To attach insert 145 to club head body 142, face member 141 is removed.Insert 145 is pushed into body 142 from the front aperture. Insert 154deforms slightly (e.g., by plastic/elastic deformation) and then snapsinto place within club body 142. As shown in FIG. 35, body 142 has band143 dimensioned to correspond to groove 147 on insert 145. Once insert145 is snapped into place, it can be held in place because an outer edgeof insert 145 deforms (compresses) to be insert, and then returns tooriginal shape such that the edge overlaps the edge of the correspondingvoid in body 142. Insert 145 can similarly be removed by squeezing itfrom a heel side and a toe side such that the outer edge compress, andthen pushing it into the inner volume of body 142 and removing it fromthe aperture at the front of body 142.

FIG. 35 shows a translucent or transparent insert 145 and FIG. 36illustrates an opaque insert 146 that functions in the same manner. FIG.37 shows an assembled club head including body 142 and insert 146 orinsert 145.

In certain embodiments, the invention provides a club head in which aface component can be separated from a body component through the use ofa threaded connection. FIGS. 38 and 39 show face member 151 and bodymember 155 with corresponding threaded portions. As shown here, facemember 151 bears male threaded member 153 and body member 155 bearsfemale threaded recess 155. Body member can be threaded onto face member153 and screwed tightly into place. In some embodiments, a club head asshown in FIGS. 38 and 39 is provided as a demonstration. For example,any part of the club head is transparent, and the threaded members allowthe club head to be separated (e.g., by unscrewing) allowing a golfer tovisually inspect an inside detail of the club head, such as layers ofconstruction of a crown, skirt, or sole. In certain embodiments, such aclub head is not meant for playing golf, but is provided primarily as atool for displaying other features in a club head. In some embodiments,such a separable club head is provided as a novelty item, such as a toyfor children, a canteen or flask, a tee case, or a gag gift or marketingprop. In certain embodiments, one of male threaded member 153 and femalethreaded recess 155 corresponds in dimensions to some commonly availablethreaded item (such as a mason jar or wide mouth drink bottle) allowinga golfer to make amusing assemblies.

In certain embodiments, the invention provides a strap-based assemblysystem that uses Velcro, snaps, clasps, or adhesives. FIGS. 40-42illustrate a club head 161 with a crown member 165 having a groove 167therein. When the crown member 165 is positioned on club head 161, firststrap 162 can be fastened to second strap 164, holding the crown member165 in place. In certain embodiments, the straps fasten by Velcro. Aclub head of the invention can have one or more straps, individually orin combination, that bind to or surround a portion of a club head forfunctional or aesthetic purposes. For example, in some embodiments, aclub head includes a strap (e.g., nylon, rubber, or leather) thatextends in a face-aft direction, as shown in FIG. 40. In certainembodiments, a strap member extends around a club head, entirely or inpart, in a heel-toe direction. Further, straps may extend in bothdirections or at angles relative to those directions. Straps may bedecorative. Straps may be used to carry weight members orelectronics-related items (e.g., devices such as shot-tracking deviceswith accelerometers or LCD screens). Straps may be provided as described(e.g., as wrapping elements) in U.S. Pat. No. 7,896,753, the contents ofwhich are hereby incorporated by reference in their entirety for allpurposes.

In some aspects, the invention provides club heads that includecantilevered attachments. FIGS. 43-49 show cantilevers.

FIG. 43 shows a face member 171 having a number of cantilever 173protruding therefrom. Body member 175, shown in FIG. 45, has a number ofrecess 177 located and dimensioned to correspond to tips 176 ofcantilevers 173. When face member 171 is mated to body member 175,cantilever tips 176 snap into place in recesses 177, fastening the clubtogether.

Either of the face member or body member may further include sets ofcorresponding tab 187 and slot 180 to aid in positioning the bodymembers together.

In some embodiments (not pictured), recesses 177 are holes through apart of the club head, and the cantilevered component can be removedfrom the component with holes by pressing in on the tips 176. It will beappreciated that this describes a functionality that is related to thatdescribed with reference to FIGS. 24 and 25. Depressable engagement pad92 and receiving hole 93 can be a related embodiment of cantilever 173and recess 177, and vice versa.

In some embodiments, a body member 175 includes decoupling holes 183. Atool 181 is provided, as shown in FIG. 44, having a prong set 185dimensioned to be inserted into decoupling holes 183. Prong set 185pushes cantilever tips 176 out of depressions 177, allowing club headcomponents to be separated from one another.

FIGS. 46-49 show configurations of cantilevered posts and recesses. FIG.46 shows a cantilever 173 having a squared tip 176 designed toinseparably couple two components of a club head.

FIG. 47 shows an angled tip 176 designed to be slid out from recess 177allowing components to be decoupled.

FIG. 48 shows another embodiment of decoupling holes 183 arranged sothat prong set 185 pushes on a distal tip of cantilever 173.

FIG. 49 shows a spring cantilever 174 having a protruding tab 178available from an outside of a club head that can be manually squeezedto decouple components of a club head.

In certain aspects and embodiments, the invention provides separablecomponents of multi-component club heads that employ a cam mechanism forreleasably joining components. FIGS. 50A-50C show a club head 301 withcomponent 305 having cam mechanism 313. As shown in FIG. 50A, club head301 has a void opening 311 dimensioned to mate with component 305. Oneportion of component engages at a perimeter of void opening 311. Here,component 305 is shown having hooks to catch bar 307. Any suitableengagement mechanism can be used. With a portion of component 305engaged at void opening 322, cam mechanism 313 can be rotated into placeto produce a fastened-together club head as shown in FIG. 50B. FIG. 50Cis a cross-section of club head 301 showing bar 307 receiving hooks ofcomponent 305, and cam mechanism 313 rotated into place.

FIG. 51 is a detail view of the cam mechanism of FIGS. 50A-50Cillustrating cam axis 321 through cam mechanism 313. FIG. 52 illustratesradii around a cam axis. In certain embodiments, as shown in FIGS.50-51, component 305 is dimensioned to engage with club head 301 suchthat some deformation of component 305 is required to remove it. Asshown in FIGS. 50A and 50C, an aft portion of component 305 bends underand forward, while an aft portion of the perimeter of void opening 311extends upwards and aft-ward. These two portions hook together (i.e.,requiring some deformation of component 305 to put it into place on clubhead 301). When cam 313 is rotated into place, it abuts a surface ofcomponent 305 and prevents the deformation of component 305 that wouldbe necessary to remove the component from the club.

As shown in FIG. 50A, cam mechanism 313 may have a tool engagementsurface 319 capable of engaging with a tool. A golfer can engage thetool with tool engagement surface 319 to have leverage from the handleof the tool to release cam mechanism 313 from the fastened position.

Turning now to FIGS. 51 and 52, the operation of cam mechanism 313 isillustrated. As shown in FIG. 52, an outer surface of cam mechanism 313defines a non-constant radius around cam axis 321. When cam mechanism313 is fastened into place on an assembled golf club, cam axis 321 isspaced away from an adjacent portion of the club head by an engagedradius Rx. Cam mechanism 313 may further be dimensioned such that, whenit is fully released (e.g., in the “up” position compared to FIG. 50A),cam axis 321 is spaced away from the adjacent portion of the club headby a minimum radius R_(min). Releasing cam mechanism 313 requirespushing it through an orientation in which cam axis 321 is spaced awayfrom the adjacent portion by a maximum radius R_(max). The relativedimensions of the radii (e.g., R_(min)<R_(X)<R_(Max)) prevents cammechanism from releasing unexpectedly. Force must be applied (e.g.,through the use of a tool) to deform component 305 enough to allowR_(Max) to pass the adjacent portion of the club head. Because cammechanism 313 presents the minimum radius to the adjacent portion whenit is in the released position. component 305 has the most space toallow for easy removal from club head 301.

In certain embodiments, the amount of deformation required to removecomponent 305 from club 301 is close to the limit of perception for mostpeople. A user may intuitively realize that they are deforming component305 to attach it and remove it, but component 305 may not exhibitsubstantial deformation. In some embodiments, deformation of component305 is elastic, plastic, or a combination thereof.

In some embodiments, a cam-based mechanism (e.g., as illustrated in FIG.51) is used with another fastening mechanism. For example, a cam can beprovided with a cantilever 173 (e.g., as illustrated in FIG. 43) suchthat, when the cam is engaged, cantilever 173 is prevented fromexhibiting any deformation such that, for example, aft component 175 isfixed to face component 171 (making reference to FIGS. 43 and 45).

In certain embodiments, a cam is integrally formed with a fasteningmember. For example, FIGS. 53A-53D show a club head 331 with cam member339 integrally formed with engagement hooks 338. As shown in FIGS.53A-53C, club head 331 includes removable crown 333 including cam member337 and removable sole 335 including cam member 339. Either or both cammember may have a tool engagement surface to be operated through the useof tool 181. FIG. 53D shows a detail view of cam member 337. Cam member337 rotates about cam axis 349 bringing engagement hook aroundengagement member 341. As shown in FIGS. 54A and 54B, engagement member341 is supported by one or more of arm 342 on club head 331. A surfaceof cam member 339 engages with a surface at a perimeter of removablesole 335 (the relevant portion of the perimeter of removable sole 335may be thickened, folded inwards, or provided with an engagement block).When cam member 339 is engaged, it cannot freely release because forceis required to push the portion of cam member 339 having R_(max) pastthe surface of the perimeter of removable sole 335. However, cam member339 can be rotated by a golfer. In some embodiments, a golfer canmanually rotate cam member 339, for example, because an elongated edgemember provides a handle or lever. In certain embodiments, a golferinserts a tool 181 into tool engagement surface 319 and uses the tool torelease the component from the golf club.

In certain embodiments, the invention provides a golf club head with aremovable component that fastens to a shaft of the golf club. Withoutbeing bound by theory, fastening a removable component to a shaft mayprovide for a very securely assembled club head due to the fact that theshaft provides a carriage function in that it carries the club head andit carries the energy of a golfer's swing. A component secured to theshaft can transmit any stress energy it is subject to through the shaftto the golfer—just as energy of impact is transmitted from a center ofpercussion at the club head to the golfer. Thus, when a golf ball ishit, the impact energy is transferred from the club head body throughthe shaft to the golfer and, simultaneously, from the separablecomponent through the shaft and to the golfer. Accordingly, fasteningthe separable component to the shaft may tend to inhibit relativestresses between the component and the club head body.

FIGS. 55A-55B show a separable component 355 for club head 351 includinga mechanism for coupling to a shaft 361 of a golf club. Club head body351 includes a cutaway, or void, dimensioned to correspond to component355. Shaft 361 extends through a hosel of club head body 351, and mayinclude a ferrule 359. Component 355 has a fastening mechanism thatincludes shaft collar 357 dimensioned to pass into club head body 351and engage a portion of shaft 361.

As shown in FIG. 55B, component 355 includes a slot that extends in avertical direction when the club is at address. When component 355 ismounted to body 351, shaft collar 357 is disposed beneath an end ofshaft 361. A golfer then lifts the mechanism, sliding shaft collar overthe end of shaft 361. FIG. 56 shows shaft collar 357. In someembodiments, shaft collar 357 has a cylindrical portion and two tabsthat extend from the cylindrical portion. In some embodiments, the twotabs are spaced apart from one another, at least proximal to thecylindrical portion, while shaft collar 357 is not subject to anystress. Sliding shaft collar 357 upwards through the slot in component355 can push the tabs together if a portion of the slot has an invertedV shape. Thus, sliding collar 357 up over shaft 361 forms a press-fitbetween collar 357 and the shaft. Once positioned so, tab 363 can beswung into a closed position, pushing post 365 into hole 369 (which canbe a press-fit or snap-fit engagement) so that collar 357 remains firmlymounted to shaft 361. In this way, component 355 is securely mounted toclub body 351 to provide a playable club.

In some aspects, the invention includes the realization and developmentof the idea that a multi-component golf club head may be provided withoptimized characteristics by coupling a component to a club head body oranother component by fastening the component to the shaft or fasteningthe component into place through the use of a mechanism that alsoprovides other functionality in the club head. A component may besecurely fastened to a club head body through integration with the shaftby a variety of suitable mechanisms. FIGS. 57 and 58A-58C illustrate amechanism for removably coupling a component to a club head body via theshaft. As seen in FIG. 58A, club head body 371 includes a cutaway voidin the crown area dimensioned to receive an insert. While illustratedhere as a portion of the crown, a cutaway void and a correspondinginsert could define any suitable portion of the club head.

Club head 371 includes hosel recess 383 dimensioned to mate with hoselinsert 387 on component 375. Component 375 is coupled to club head body371 by inserting hosel insert 387 into hosel recess 383 to form anassembled club head 390 as shown in FIGS. 58A-58C. As can be seen inFIG. 57, the cutaway void in club head body 371 has a flange around atleast a portion of the perimeter of the void.

Further, as illustrated in FIG. 58A, the cutaway void and the component375 have corresponding wavy edges. The perimeter edge of the cutawayvoid is wavy in that it defines one or more lobe 377 corresponding tocomplementary wavy portion of component 375. The wavy portion ofcomponent 375 may further include a webbed portion 379 to slip underlobe 377 to help position component 375 correctly and hold it in place.One insight of the invention is that coupling lines in conformationsother than straight may provide unexpected benefits in terms ofdurability, ease of assembly, sound tuning, among other things. Morewill be said about non-straight coupling seams below.

Assembled club head 390 may be fastened together for playing by anysuitable mechanism. In certain embodiments, club head 390 takesadvantage of an interchangeable or repositionable shaft that may, forexample, also provide other functionality to a golf club (such asmultiple loft angles or different shaft lengths). Interchangeable andrepositionable shafts are discussed elsewhere herein. In certainembodiments, a shaft with a fixed ferrule is inserted into the hosel ofcomponent 375. Club head body 371 has a bore, or hole, for a shaftsleeve screw in the heel region of the sole. A shaft sleeve screwextends through the club head and threads into an end of the shaft. Whenthe shaft sleeve screw is tightened, a compressive force is exertedbetween the fixed ferrule and the screw head/washer, thereby firmlygripping component 375 to club head body 371. Other mechanisms forcoupling the shaft and ferrule to body 371, thereby holding component375 in place, may include a bayonet mounting mechanism with J-shapedslots (see, e.g., U.S. Pub. 2010/0261543, the contents of which arehereby incorporated by reference in their entirety for all purposes), athreaded portion in hosel recess 383 corresponding to a threaded memberon the shaft (see, e.g., U.S. Pat. No. 7,819,754, the contents of whichare hereby incorporated by reference in their entirety for allpurposes), or other methods known in the art. Mechanisms for golf clubssuitable for operation with the invention, are discussed in U.S. Pub.2010/0041493; U.S. Pub. 2011/0098128; U.S. Pat. No. 8,057,323, U.S. Pat.No. 1,879,117 and U.S. Pat. No. 3,096,982, incorporated by referenceherein in their entirety.

As discussed above, in certain embodiments, a component mates with aclub head body or with another component via a non-straight seam line(e.g., not a straight line when viewed along a surface of an assembledclub head). FIGS. 58A-58C and FIG. 59 show embodiments includingnon-straight seams. In some embodiments, coupling seams include wavylines. Wavy can include, for example, lines that—when projected onto asurface—have at least three inflection points that can be connected byan arc. Wavy can include lines or edges that may generally be describedas lobed, scalloped, or wavy.

One insight of the invention is that a golf company may desire toprovide a family of similar, but not identical, club heads, each havinga separable component. For example, a golf company may provide twodrivers having the same model name, wherein one is a few cubic cm largerthan the other (e.g., men's and women's models). Each club head can beprovided with a separable component that has a functionally similarcoupling mechanism and occupies a similar portion of an assembled clubhead. To avoid golfer confusion, different clubs can be provided withdistinct wavy line patterns in the coupling seams. For example, the 455cubic cm driver may have a wavy assembly seam line with three lobes onthe club head body that interlock with two lobes on the separablecomponent, whereas a 425 cubic cm driver may have a “tight wave”assembly seam line with seven lobes on the club head body that interlockwith six lobes on the component. Through this mechanism, the separatedcomponents will each have a distinct appearance such that a golfer caneasily reach for and pick up only the appropriate one when assembling agolf club.

For example, according to this example, a golfer who owns the 425 cubiccm model could enter a pro-shop seeking to purchase a newly-releasedcomponent with some attractive feature (such as a translucent materialin the component that reveals a digital LED screen of an electroniccomponent within the club head). Knowing that their club head includedthe seven-lobed edge, the golfer—when looking at the components in thedisplay case—can easily focus their attention on only those that fitwith their club head.

Moreover, it is an insight of the invention that wavy lines may providefunctional and structural advantages. For example, when coupling acomponent to a club head body (e.g., outdoors in the elements), it maybe easier to achieve a proper fitting (i.e., easier to “seat” the partin place) if the wavy edges guide the component into the proper seating.

Further, the stability of the coupling of multi-components may belimited by degrees of freedom of relative motion between the twocomponents. For example, when a cross sectional-profile of a componentis curved (see, e.g., component 26 in FIG. 2), coupling the component tothe club head body may leave open certain degrees of freedom (e.g.,lateral translation in a front-back direction of the component relativeto the club head). Providing a wavy coupling seam as shown in FIG. 58Acan remove a degree of freedom of relative translation, therebyincreasing the security of the coupling of the multiple club headcomponents.

Beyond aiding a golfer in seating a component, and removing degrees offreedom to prevent uncoupling, a wavy seam may provide mating contactlines and surfaces that are oriented desirably relative to a directionof propagation of an impact-associated wave of compression energy. Whena club head strikes a ball with force, energy may be transferred throughthe club head as compression waves that propagate through the materials.Where the waves encounter boundaries between separate components, theymay reflect or refract in an undesired fashion if the wave-boundaryintersection defines solely and only one certain angle (e.g., less than45°). For example, given that driver heads may have shapes that havebeen optimized by generations of engineering design, placing a couplingseam between two components along a substantial portion of the driverhead may interfere with impact wave propagation in ways that adverselyaffect the playability of a club, for example, diminishing itscoefficient of restitution, contributing to rapid materials fatigue, orcausing very uncomfortable transmissions of vibrations to a golfer'sarms. Providing wavy boundaries may tend to preserve the existing,optimized energy propagation characteristics of a club head withmulti-component construction.

FIG. 59 shows a club head with multi-component construction in which aboundary seam between component 389 and club head body 381 is wavy. Clubhead body 381 includes a cutaway void space dimensioned to receivecomponent 389. The void space may bear one or more of support flange 386spaced around the perimeter. The wavy edge generally defines a series oflobe 377. Component 389 may be provided with webbed portion 379corresponding to lobe 377 and fitted to extend under an edge of lobe377, holding component 389 in its proper place in an assembled clubhead. As shown in FIG. 59, component 389 includes a snap-fit mechanism388 for removably coupling the component to the club head. FIG. 60 showsa cross-sectional view of snap-fit mechanism 388. Cantilever 60 includesa protrusion that can mate with slot 58. In certain embodiments, aportion of cantilever 600 can be manually manipulated from the outsideof an assembled club head to release component 389 from club head body381.

In some aspects, the invention provides a club head with multi-componentconstruction in which a component includes a malleable material such asrubber. FIG. 61 shows a club head 393 with a malleable component 395capable of being pulled away from the club head by a peeling, orfolding-back action. In some embodiments, as shown in FIG. 61, one edgeof a malleable component is permanently fixed the club head (e.g.,through cement, or rivets, or similar suitable attachment mechanism). Inother embodiments, malleable component 395 is fully removable from clubhead 393 (e.g., for replacement/interchangeability with anothercomponent).

As shown in FIG. 61, malleable component 395 includes a gasket ring 397.Club head 399 bears a corresponding boss portion 399. In someembodiments as shown in FIG. 61, boss portion 399 is rigid (e.g.,plastic, metal, or composite) and dimensioned to be pressed into aninternal space of gasket ring 397. The pressure between gasket ring 397and boss portion 399 creates a press-fit that holds component 395 toclub head 393 during play. Boss portion 399 can provide functionality tothe club head. For example, in certain embodiments, boss portion 399surrounds a feature such as an opening into the club head, aweight-mounting port, or a mini-USB port. An opening can be providedthat allows a golfer to insert a tool into the club head to interactwith some other feature within the club head, such as, for example, atunable mass-distribution mechanism or an assembly tool similar to theone depicted in FIG. 29.

FIGS. 62A and 62B show use of a flap component to fasten a separablecomponent to club head body. As shown in FIG. 62A, club head body 409includes a cutaway void space dimensioned to receive insert 401. Theperimeter of the void space includes one or a number of mounting flanges411 that can hold insert 401 in place. Further, a portion of insert 401my include one or number of mounting tabs dimensioned to slip under anedge of the perimeter of the void space. Insert 401 includes a bossportion 399 dimensioned to mate with gasket ring 397 on malleablecomponent 395.

As shown in FIG. 61B, insert 401 can be positioned in the cutaway spaceof club head 409. Then, malleable component 395 can be used to fasteninsert 401 in place, for example, through the use of a press fit betweengasket ring 397 and boss portion 399. While insert 401 is here shown ashaving a wavy perimeter edge to mate with a corresponding wavy edge ofthe perimeter of the cutaway void in club head 409, this is just oneillustrated embodiment. Insert 401 can have any suitable shapeincluding, for example, a rectangle (e.g., to cover a compartment fortwo AA or AAA batteries), circular (e.g., to cover a screw or weightport), or irregular (e.g., to provide access to some interior mechanismor mass-distribution assembly).

Use of one component to aid in connecting another component allows forbenefits in design and manufacturing that may not otherwise be availableto club head designers. For example, when an assembled club headincludes a separable component joined to the club head body (or anothercomponent) along an attachment perimeter, if a portion of the attachmentperimeter is covered (for example, by a flexible flap 395), that portionmay be manufactured to less precise manufacturing tolerances than if itwere uncovered in an assembled, playable club head.

To illustrate, FIG. 61B shows insert component 401 assembled to clubhead body 409. An aft edge of insert 401, as shown, does not meet andmate with the perimeter of the cutaway void space in club head body 409.However, when flexible flap 395 is pushed into place, no gap betweeninsert 401 and club head body 409 will appear under visual inspection.Accordingly, in certain embodiments, the invention provides a club headhaving a club head body and a separable insert in which an outerperimeter of the insert and an inner perimeter of a cutaway space in thebody define an attachment perimeter. When the insert is coupled to thebody, they make contact along a portion of the attachment perimeter andthey are optionally spaced away from one another along a portion of theattachment perimeter. Another component of the club head is provided tocover the spaced away portion of the attachment perimeter such that,when the club head is fully assembled, no gaps are visible from theoutside of the club head. This allows club head body 409 to be designedand manufactured with a cutaway provided to receive an insert. Then,insert 401 can be designed or manufactured with less stringent attentiongiven to the fit along a portion of the insert, which may allowmanufacturing to be faster or less expensive.

In some aspects, the invention provides a component for a club head thatforms an assembled, playable club head through the use of magnets. Forexample, FIG. 63 shows a club head body 501 having a cutaway portionwith a protruding flange defining slot 507. A separable sole member 505has protruding tabs 509 dimensioned to slide into slot 507 to form anassembled club head. Each of club head body 501 and sole member 505 haveone or more of boss 513, shown here on an inside surface, holding atleast one magnet 523. Any magnet may be used in the invention. In someembodiments, a high-strength magnet such as a rare earth magnet is used(e.g., magnets including neodymium or samarium-cobalt). Magnet 523 canbe press-fit into boss 519, held in place by adhesives, threaded in, orheld in place by any other suitable method (including, for example,being embedded in plies of pre-peg using, for example, manufacturingmethods as discussed in U.S. Pat. No. 6,695,608 the contents of whichare hereby incorporated by reference in their entirety for allpurposes). Further, magnets may be employed to fix a mass element inplace, such as a mass ring as disclosed in U.S. Pub. 2011/0081986, thecontents of which are incorporated by reference herein in their entiretyfor all purposes.

FIG. 64 is a top-down view of boss member 513 with magnet 523 therein.As can be seen from FIG. 64, boss 513 can be positioned to expose asurface of a magnet for interaction with another magnetic material.

FIG. 65 shows another embodiment of the invention using magnets tofasten a component to a club head. Here, insert panel 605 is hooked intoclub head body 601 via a flange on insert panel 605 received by slot607. Distal to the flange is a mating surface presented bymagnet-including bosses on insert 605 and club head body 601. Looking,for example, at club head body 601, a boss portion 609 extends upwardsand includes magnet 613 mounted therein (for example, by one of themethods mentioned above).

Magnetized coupling points can be positioned at any suitable location ona club head. In certain embodiments, separable components are designedto be held in place through the use of magnets that, when on anassembled club head, are located so as to optimize mass distribution(e.g., to increase MOI around a center of percussion on a strike face orto lower a center of gravity).

FIGS. 66-68 illustrate another embodiment using magnets to couple aninsert to a club head body. Here, insert 705 is coupled to club headbody 701 through one or more of protruding post 706 dimensioned to bereceived by corresponding slot 708. An aft end of inert 705 includes oneor more of magnet 709 (not visible in FIG. 66) exposed on an undersidethereof. Club head body 701 further includes one or more of magnet 707.FIG. 68 is a face-aft cross sectional view through magnetic couplingmechanism of insert 705 and club head body 701. Magnet 709 in insert 705matches up to magnet 707 in club head body 701, thereby fastening theclub together for playing golf.

The disclosure herein includes description and discussion of methods andmechanism for assembling components such as inserts, sole plates, crownplates, and components of club heads, and bodies, to one another. Theinvention includes the insight that one or more of any of any mechanismof the invention, any component of the invention, or any feature of theinvention can be combined in any number and in any combination. Forexample, any given flange arrangement and any given fastening mechanismmay be combined—even if not shown together in a figure of the presentdisclosure—to provide a multi-component club head or club head withseparable component or insert. Thus a club head of the present inventionmay include, for example, barbed posts designed to be broken off toremove a component as well as magnets for fastening components together.

It is an insight of the invention that a number of aspects of a clubhead can be uniquely selected with a variety of options and that this iswell suited to customizing club heads to a customer's desires. It is arelated insight that computer device technology provides a valuable toolfor managing the complexity of manufacturing where customized orders areincluded. Accordingly, the invention provides systems and methods forproviding a customized club head.

Providing a customized head can include offering options for one or morefeatures that are available with a club head and receiving a selectionfrom a consumer of an option. FIG. 69 depicts a display that can be usedto receive a consumer's selection of one or more options for a clubhead. As shown in FIG. 69, a consumer could be given a display (e.g., ina web browser as presented via a graphical user interface (GUI)) thatincludes elements such as pull-down menus for choosing options. Anymethod of offering options and receiving selections is included, suchas, for example, point-and-click selection, keyboard entry, radiobuttons, and confirmation of suggested options. A selection of an optioncan include selecting a given option from a set of possibilities and itcan also include selecting whether or not to include a certain featureat all. For example, a consumer can be offered whether or not they wouldlike a removable crown panel on their club head and, if they choose so,they can then be offered a list. Options can be offered and selectionsreceived for any aspect of a club head including all of those discussedherein. As indicated in FIG. 69, a consumer could choose a material fora crown panel and suitable choices could include, for example, clearplastic, translucent plastic, composite, carbon fiber, titanium,aluminum, alloy.

A customer could be offered choices of bodies and body materials.Choices of certain bodies may govern the availability of certain otherchoices. For example, some bodies may have a forward member forsupporting a strike face and a body skirt member upon which a crownpanel and sole plate are to be installed. Where a customer chooses sucha body, they may then be offered a choice of sole plate (e.g., withchoice of style, material, color, etc.).

Other features a customer could choose options for include overallfinish of surface (e.g., anodized, painted, decal set), strike face,removable/interchangeable weight members, reconfigurable shaft, settingindicator window, customer-uploaded photo printed on surface (e.g., asuploaded digitally), number of club heads (e.g., customer orders entireset or matching clubs/sets for whole families), etc.

FIG. 69 generally shows an exemplary display as could be shown on ascreen, for example, of a computer or smartphone, discussed in moredetail below. In certain embodiments, FIG. 69 represents a displayrendered in a web browser (e.g., a web page being displayed by InternetExplorer or Google Chrome).

As shown in FIG. 69, receiving customer options can be done via a seriesof related screens. For example, a customer can choose materials forparts in a first screen, choose optional accessories in another screen,and save their choices and pick colors in another screen. However, inother embodiments, all choices are made on a single screen or adifferent combination of screens. In certain embodiments, choices aresuggested based on inferences made according to computer program rulesabout a customer's likely preference. For example, if a customer ordersa shaft in a given color (e.g., orange), a club head can be shown andsuggested with a given matching or complementary color (e.g., orangemain material with blue contrast finish details, or all green panels).

Given the variety of options a customer may choose and the variety ofnumbers a customer may order, the invention provides methods ofreceiving and preparing customized orders. FIG. 70 gives a high-levelblock diagram of steps of a method of providing a customized club headaccording to certain embodiments of the invention. A method of providinga customized club head according to certain embodiments of the inventioncan include receiving a customer's choice of a product (e.g.,AMP-product line driver club head) and showing the customer a productexample (e.g., FIG. 69). A customer's selections of an option arereceived and saved in a memory. If the selection reflects a change fromwhat was previously shown, the displayed product view can be updated toshow what the customer has chosen. This can be repeated for as manyfeatures as are customizable or as many features as the customer choosesto select options for.

If the customer ends up not placing an order, they can be returned tobrowsing (e.g., shown a web page home screen or another product screen).Their choices can be saved and displayed to them at a later web pagevisit.

If the customer places an order, methods of the invention includecapturing information from the customer about how they will pay for theproduct and how they will receive it. For example, a customer canprovide a credit card number over a computer network (e.g., by typinginto a payment web page), and then choose shipping by expedited mail andprovide their home address. Or, alternatively, a customer can indicatethat they wish to use a corporate account (e.g., they are purchasing adozen club heads that are printed with a corporate logo which they haveuploaded an image file such as a TIFF) and they can specify delivery tosome site. A customer can also choose in-store pickup. In certainembodiments, a method of providing a customized club head is operable inconjunction with a special event, and methods include capturing deliveryinformation about providing the club heads at the special event. Forexample, if Acme Golf Co is sponsoring and staffing a booth at CorporateInc.'s charity fund-raiser, Acme Golf Co can collect information from aperson at Corporate Inc. about a customized golf club (e.g., as apromotional item or prize) via methods of the invention, and Acme GolfCo can bring the golf club to the booth at the charity fund-raiser.

After delivery information is captured, it is determined whether theordered item is already in stock, as-ordered. If it is, the ordered itemis shipped or prepared for delivery according to the customer's deliveryinformation. If the ordered item is not in stock, the order is batched.

Methods of the invention include organizing sets of orders for efficientproduction. A computer program, executed by a processor, can makereference to information about production facilities to organize aplurality of different orders and to coordinate production instructionsso that production facilities include minimal down-time while componentsor parts are “switched out”. For example, if regular production isscheduled for ten gross of aluminum club head bodies and ten gross oftitanium club head bodies, and customized orders have been placed forone composite body, one aluminum body, one titanium body, and one alloybody, then order batching can include listing the order, for example, inthe following order: 1441 aluminum; 1441 titanium; lcomposite; 1 alloy.

Order batching further includes scheduling production of individualbatches, where a batch is a sub-set of all orders identified by acomputer executing program instructions according to productioncriteria. Batches may be scheduled according to information aboutproduction times, steps, complexity, or interrelationships involved. Forexample, if a repositionable shaft connection is required to be added toa club head at an assembly workstation where a main body of a club headis painted, while a sole plate is added to a club head at a dedicatedseparate workstation and can only be added after a main body is painted,then a batch can be prepared that is all club heads with repositionableshaft connections batched with all club heads to be painted, while aseparate batch is prepared that includes all club heads with a soleplate. Then, the second batch can be routed to the main assembly workstation first, for example, to leave additional time for adding therepositionable shaft connection to that batch while the other batch isat the main assembly workstation so that the entire set of batches iscompleted at the same time.

After order batching, order information (e.g., info regarding batches,production schedules, and individual orders of club heads) istransmitted to a production system or facility, and the ordered clubheads are produced.

After production, the club heads are sent. If a customer has ordered aclub to be shipped to their home, the club is sent to the customer. If acustomer has requested in-store pickup, the club is sent to the store.If a customer has requested another delivery option, it is so initiated.

The invention provides systems suitable for implementing methods ofproviding a customized golf club including the foregoing methods. FIG.71 shows components in an exemplary system for providing a customizedgolf club. As shown in FIG. 71, system 200 generally includes one ormore computer, communicably coupled via network 215. Systems and methodsof the invention may generally be implemented through the use of one ormore computer such as any combination of a provider computer 281, aproduction computer 261, and a consumer computer 201 along with, forexample, a sales server 241 and a production server 221. A computergenerally includes a processor (e.g., 209, 289, 269, 249, 229) operablycoupled to a memory (e.g., 207, 287, 267, 247, 227) and configured tosend or receive information via input-output device (e.g., 205, 285,265, 245, 225).

One of skill in the art will recognize that a processor may be providedby one or more processors including, for example, one or more of asingle core or multi-core processor (e.g., AMD Phenom II X2, Intel CoreDuo, AMD Phenom II X4, Intel Core i5, Intel Core i& Extreme Edition980×, or Intel Xeon E7-2820). In certain embodiments, any of consumercomputer 201, provider computer 281, production computer 261 may be anotebook or desktop computer sold by Apple (Cupertino, Calif.) or adesktop, laptop, or similar PC-compatible computer such as a DellLatitude E6520 PC laptop available from Dell Inc. (Round Rock, Tex.).Such a computer will typically include a suitable operating system suchas, for example, Windows 7, Windows 8, Windows XP, all from Microsoft(Redmond, Wash.), OS X from Apple (Cupertino, Calif.), or Ubuntu Linuxfrom Canonical Group Limited (London, UK). In some embodiments, any ofconsumer computer 201, provider computer 281, production computer 261may be a tablet or smart-phone form factor device and processor 281 canbe provided by, for example, an ARM-based system-on-a-chip (SoC)processor such as the 1.2 GHz dual-core Exynos SoC processor fromSamsung Electronics, (Samsung Town, Seoul, South Korea).

In some embodiments, either of sales server 241 or production server 221can be a Hitachi Compute Blade 500 computer device sold by Hitachi DataSystems (Santa Clara, Calif.). Either of processor 249 or processor 229can be, for example, a E5-2600 processor sold under the trademark Xeonby Intel Corporation (Santa Clara, Calif.).

Input-output devices generally includes one or a combination of monitor,keyboard, mouse, data jack (e.g., Ethernet port, modem jack, HDMI port,mini-HDMI port, USB port), Wi-Fi card, touchscreen (e.g., CRT, LCD, LED,AMOLED, Super AMOLED), pointing device, trackpad, microphone, speaker,light (e.g., LED), or light/image projection device.

In certain embodiments, a consumer's selection of options is receivedvia the consumer's use of consumer computer 201 and the selection isreceived at sales server 241 and stored in memory 247. Sales server 241uses a network card for input/output 245 to received data. Sales server241 maintains order database 243 which may include accounts 244 whereconsumer information is stored (e.g., for payment and deliveryinformation).

After orders are received and ready for production, digital files can betransferred via input/output 245 from sales server 241 to productionserver 221 via input/output 225, which may also be a network card orother data transfer mechanism. Order information (e.g., orders 239) isstored in production database 235 in memory 227. Processor 229 executescomputer program instructions stored in memory 229 to perform orderbatching and to initiate production.

A production facility may be equipped with a production computer 261which either automatically coordinates the operation of machines orprovides information to production employees, e.g., via input/output265, which could include, for example, a monitor or laser printer.

Many of the steps and functions described herein can be planned orcoordinated by a provider personnel using provider computer 281. Forexample, engineers or sales personnel can prepare and upload information(e.g., digital files such as in a comma-separated values (CSV) format)that, for example, lists options for features for consumer selection.That is, in certain embodiments, provider personnel use providercomputer 281 to “set up” what options are available, for example, withina display such as the one shown in FIG. 69. Such uploaded informationmay be saved in memory 247 on sales server 241 and can be used, forexample, by processor 249 to cause a display to be rendered such as thatshown in FIG. 27 on input/output 205 on consumer computer 201.Input/output 205 can include a monitor displaying a view of a webbrowser. A customer's selection of options can be stored in one ofaccounts 244 in order database 243 by writing a file in memory 247.

A memory generally refers to one or more storage devices for storingdata or carrying information, e.g., semiconductor, magnetic,magneto-optical disks, or optical disks. Information carriers for amemory suitable for embodying computer program instructions and datainclude any suitable form of memory that is tangible, non-transitory,non-volatile, or a combination thereof. In certain embodiments, a deviceof the invention includes a tangible, non-transitory computer readablemedium for memory. Exemplary devices for use as memory includesemiconductor memory devices, (e.g., EPROM, EEPROM, solid state drive(SSD), and flash memory devices e.g., SD, micro SD, SDXC, SDIO, SDHCcards); magnetic disks, (e.g., internal hard disks or removable disks);magneto-optical disks; and optical disks (e.g., CD and DVD disks). Theprocessor and the memory can be supplemented by, or incorporated in,special purpose logic circuitry.

The subject matter described herein can be implemented in a computingsystem that includes a back-end component (e.g., sales server 241 orproduction server 221), a middleware component (e.g., an applicationserver or sales sever 241), or a front-end component (e.g., consumercomputer 201 having a graphical user interface or a web browser throughwhich a user can interact with an implementation of the subject matterdescribed herein), or any combination of such back-end, middleware, andfront-end components. The components of the system can be interconnectedthrough network 215 by any form or medium of digital data communication,e.g., a communication network. Examples of communication networksinclude cell network (e.g., 3G or 4G), a local area network (LAN), and awide area network (WAN), e.g., the Internet.

The subject matter described herein can be implemented as one or morecomputer program products, such as one or more computer programstangibly embodied in an information carrier (e.g., in a non-transitorycomputer-readable medium) for execution by, or to control the operationof, data processing apparatus (e.g., a programmable processor, acomputer, or multiple computers). A computer program (also known as aprogram, software, software application, app, macro, or code) can bewritten in any form of programming language, including compiled orinterpreted languages (e.g., C, C++, Perl), and it can be deployed inany form, including as a stand-alone program or as a module, component,subroutine, or other unit suitable for use in a computing environment.Systems and methods of the invention can include instructions written inany suitable programming language known in the art, including, withoutlimitation, C, C++, Perl, Java, ActiveX, HTML5, Python, Ruby on Rails,Visual Basic, or JavaScript. In certain embodiments, systems and methodsof the invention are implemented through the use of a mobile app. Asused herein, mobile app generally refers to a standalone program capableof being installed or run on a smartphone platform such as Android, iOS,Blackberry OS, Windows 8, Windows Mobile, etc.

Functionality of the invention can be implemented by a mobile app or asoftware application or computer program in other formats includedscripts, shell scripts, and functional modules created in developmentenvironments.

A computer program does not necessarily correspond to a file. A programcan be stored in a portion of a file that holds other programs or data,in a single file dedicated to the program in question, or in multiplecoordinated files (e.g., files that store one or more modules,sub-programs, or portions of code). A computer program can be deployedto be executed on one computer or on multiple computers at one site ordistributed across multiple sites and interconnected by a communicationnetwork.

A file can be a digital file, for example, stored on a hard drive, SSD,CD, or other tangible, non-transitory medium. A file can be sent fromone device to another over network 215 (e.g., as packets being sentbetween a server and a client, for example, through a Network InterfaceCard, modem, wireless card, or similar).

Writing a file according to the invention involves transforming atangible, non-transitory computer-readable medium, for example, byadding, removing, or rearranging particles (e.g., with a net charge ordipole moment into patterns of magnetization by read/write heads), thepatterns then representing new collocations of information aboutobjective physical phenomena desired by, and useful to, the user (e.g.,a physical arrangement of particles that indicates that a specific, newclub head is to be constructed from a certain set of multiple componentsand sent to a customer). In some embodiments, writing involves aphysical transformation of material in tangible, non-transitory computerreadable media (e.g., with certain optical properties so that opticalread/write devices can then read the new and useful collocation ofinformation, e.g., burning a CD-ROM). In some embodiments, writing afile includes transforming a physical flash memory apparatus such asNAND flash memory device and storing information by transformingphysical elements in an array of memory cells made from floating-gatetransistors. Methods of writing a file can be invoked manually orautomatically by a program or by a save command from software or a writecommand from a programming language.

As used herein, the word “or” means “and or or”, sometimes seen orreferred to as “and/or”, unless indicated otherwise. Any documentsreferenced in the disclosure are hereby incorporated herein by referencein their entirety for all purposes.

Although these inventions have been disclosed in the context of certainpreferred embodiments and examples, it will be understood by thoseskilled in the art that the present inventions extend beyond thespecifically disclosed embodiments to other alternative embodimentsand/or uses of the inventions and obvious modifications and equivalentsthereof. In addition, while several variations of the inventions havebeen shown and described in detail, other modifications, which arewithin the scope of these inventions, will be readily apparent to thoseof skill in the art based upon this disclosure. It is also contemplatedthat various combinations or sub-combinations of the specific featuresand aspects of the embodiments can be made and still fall within thescope of the inventions. It should be understood that various featuresand aspects of the disclosed embodiments can be combined with orsubstituted for one another in order to form varying modes of thedisclosed inventions. Thus, it is intended that the scope of at leastsome of the present inventions herein disclosed should not be limited bythe particular disclosed embodiments described above.

Any patent or publication mentioned herein is hereby incorporated byreference in entirety for all purposes.

What is claimed is:
 1. A golf club head, comprising: a body membercomprising at least one opening for receiving a crown insert, the bodymember comprising at least one body attachment feature for attaching thebody member to the crown insert; and a crown insert attached to the bodymember, a majority of the crown insert comprised of plastic, the crowninsert comprising at least one crown attachment feature for attachingthe crown insert to the body member, the crown insert comprising atleast one divider element separating the crown insert into a pluralityof plastic portions.
 2. The golf club head of claim 1, wherein theplastic portions are transparent.
 3. The golf club head of claim 1,wherein the divider elements are flexible, non-plastic, and divide thecrown insert into four plastic sections.
 4. The golf club head of claim1, further comprising a releasable weight component releasably attachedto the body member, the releasable weight component having at least onespecialized tool cavity, the releasable weight component configured toadjust the weight and center of gravity of the club head.
 5. A golf clubhead, comprising: a body comprising an opening for receiving an insert;an attachment feature disposed at the opening and presenting a surfacecomprising a plurality of holes; and an insert panel comprising aplurality of protrusions dimensioned to be received by the plurality ofholes.
 6. The golf club head of claim 5, wherein the body comprises atleast five holes on the surface, and the insert comprises at least fivepost-like structures.
 7. The golf club head of claim 5, wherein surfacecomprising a plurality of holes is located on a gasket member, and thegasket member is attached adhesively to the body.
 8. The golf club headof claim 5 wherein the insert is a crown insert comprising a majority ofthe crown, and is comprised at least partially of plastic.
 9. A golfclub head, comprising: a body member comprising at least one opening forreceiving a sole insert, the body member comprising a first attachmentflange disposed at the opening for attachment to the sole insert; and asole insert comprising a second attachment flange and attached to thebody via the first attachment flange, wherein the sole insert isconfigured to be attached to the body member by a snap-fit assembly,without the use of adhesives or welding.
 10. The golf club head of claim9, wherein first attachment flange extends inwardly from the body membertowards an open cavity in the club head.
 11. The golf club head of claim9, wherein the first and second attachment flanges are angled.
 12. Thegolf club head of claim 9, wherein the snap-fit assembly comprises aplurality of cantilevers with protruding tips and a recess correspondingto each tip.
 13. The golf club head of claim 9, wherein the snap-fitassembly comprises a collar adapted to be swaged onto a post forattachment and unscrewed with a wrench for removal.
 13. The golf clubhead of claim 9, further comprising at least one weight releasablyattached to the body member, the weight having at least one specializedtool cavity, the weight screw configured to adjust the weight and centerof gravity of the club head.
 14. The golf club head of claim 9, whereinthe sole insert is selected from a group of different inserts, so as tocustomize the club head.
 15. A golf club head comprising: a body memberhaving a striking face, a heel-side skirt portion, a toe-side skirtportion, and a hosel; a shaft-mounting structure within the body memberfor coupling a shaft through the hosel; a shaft bolt configured tofasten an end of the shaft within the body; and a sole insert fastenedin place at least in part by the shaft bolt.
 16. The club head of claim15, wherein removing the shaft bolt with a tool allows the sole insertto be manually separated from the club head with no other tools.
 17. Agolf club head comprising: a body member having strike face area, ahosel, and an opening having a perimeter; a weight member releasablyattached to the body member; and an insert panel releasably held inplace over the opening at least in part by the weight member.
 18. Theclub head of claim 17, further comprising a flange disposed at theperimeter of the opening and further wherein the insert panel comprises:a hole through which a portion of the weight member extends whenattached to the body member; an attachment feature spaced away from thehole for coupling to the body member.
 19. A set of inserts forcustomizing a golf club, the set comprising: at least two insert panelseach having an exterior surface, an interior surface, and a perimeterportion; and an attachment feature at the perimeter portion of eachinsert panel, wherein the two insert panels have substantially the samemorphology at the perimeter portion and are adapted to beinterchangeably coupled to a club head, and further wherein the twoinsert panels are not identical.
 20. The set of claim 19, wherein atleast one of the insert panels is translucent.
 21. The set of claim 19,wherein the attachment feature comprises one selected from the listconsisting of: barbed posts; adhesive; protruding boss for coupling viaa shaft screw; recess for receiving a protruding tip of a cantilever;and swage-on/twist-off fastening mechanism.
 22. The set of claim 19,wherein the two insert panels further comprise unlike morphologies attheir exterior surfaces.
 23. The set of claim 19, further comprising athird insert panel.
 24. A method of providing a customized golf clubhead, the method comprising: receiving a consumer's selection of anoption and storing the selection in a tangible, non-transitory memory;creating, through the use of a computer processor coupled to the memory,a digital file including information about a club head including theselected option; transferring the information to a production site; andproducing a customized club head including the selected option.
 25. Themethod of claim 24, wherein the consumer's selected option comprises achoice of insert to be provided with the club head.
 26. A system forproviding a customized golf club, the system comprising: a computerincluding a tangible, non-transitory memory coupled to a processor, thecomputer configured to execute instructions causing it to: receive aconsumer's selection of an option and store the selection in a tangible,non-transitory memory; create, through the use of a computer processorcoupled to the memory, a digital file including information about a clubhead including the selected option; transfer the information to aproduction site; and write a file comprising billing and shipping datafor use in a sale transaction.
 27. A golf club head, comprising: a bodymember comprising an opening dimensioned to receive an insert; a borethrough the hosel and a sole portion of the club head to receive aremovable shaft; and an insert dimensioned to fit into the opening toform an assembled club head, wherein the insert is fastened into placeby fastening a shaft to the assembled club head.
 28. A golf club head,comprising: a body member comprising an opening dimensioned to receivean insert; an insert having an outer perimeter portion configured tomate with an inner perimeter portion of the opening to define anattachment perimeter, wherein at least a portion of the attachmentperimeter defines a line that, when projected onto a plane, comprisesthree inflexion points that can be connected with an arc having noinflexion points in the plane.
 29. A golf club head comprising: a bodymember comprising a feature for mating with a malleable component; and amalleable component adapted to mate with the feature to provide anassembled club head.
 39. The club head of claim 29, wherein themalleable component comprises rubber and the feature is a raised, rigidboss.
 40. A golf club head, comprising: a body member comprising anopening dimensioned to receive an insert; an insert adapted to becoupled to the opening to provide an assembled club head; and afastening mechanism including a cam that fastens the insert to theassembled club head.
 41. The club head of claim 40, wherein the cam ispart of a lever member having a tool engagement surface.
 42. The clubhead of claim 40, wherein the fastening mechanism further includes atleast one engagement hook.
 43. A golf club head, comprising: a bodymember comprising an opening dimensioned to receive an insert; an insertadapted to be coupled to the opening to form an assembled club head fora golf club and further wherein the insert includes a mechanism forfastening the insert to a shaft of the golf club.